Title of Invention

METHOD FOR PRODUCTION OF ACRYCLIC ACID .

Abstract A method for producing acrylic acid from an acrylic acid-containing solution of high concentration without performing azeotropic distillation is provided. This method of producing acrylic acid comprises steps of absorbing acrylic acid-containing gas, distilling the acrylic acid-containing solution without using an azeotropic solvent thereby obtaining crude acrylic acid as a column bottom stream and/or a column side stream, and supplying the crude acrylic acid to a crystallizing step and melt crystallizing the crude acrylic acid thereby obtaining purified acrylic acid.
Full Text BACKGROUND OF THE INVENTION
Field of the Invention:
This invention relates to a method for producing acrylic
acid by distilling an acrylic acid-containing solution
without using an azeotropic solvent, obtaining crude acrylic
acid as a column bottom stream and/or a column side stream
of a distillation column, and then crystallizing the crude
acrylic acid.
Description of the Related Art:
Commercial production of acrylic acid generally resorts
to the method of propylene oxidation which consists in
subjecting propylene and/or acrolein to catalytic gas phase
oxidation. When acrylic acid is produced by this method of
propylene oxidation, the step of propylene oxidation gives
rise to such impurities as water, acids like propionic acid,
acetic acid, and maleic acid, and aldehydes like acetone,
acrolein, furfural, and formaldehyde in the form of
by-products. The gas containing these by-products is
absorbed as an acrylic acid-containing solution generally
via contact with an absorbent and obtainedthe solution is
subsequently separated the absorbent by distillation etc.
One known method, for example, produces acrylic acid
of high purity by absorbing an acrylic acid-containing gas
resulting from catalytic gas phase oxidation with a high
boiling solvent, distilling the acrylic acid-containing
solution thereby separating it into the solvent and crude
acrylic acid, and subsequently subjecting the crude acrylic
acid to a process of crystallization (JP-A-1997-227445) .
• This method comprises carrying out a step of absorption of
an acrylic acid-containing gas after the gas has been cooled
with a venturi, carrying out a step of removing a low boiling
compound subsequent to the step of absorption, thereafter
separating the acrylic acid-containing solution in a
distillation column into a high boiling substance and a low
boiling substance, withdrawing crude acrylic acid as a liquid
via the intermediary stage of the column, and purifying the
crude acrylic acid by a step of crystallization.
When an aqueous solution can be used as an absorbent
for acrylic acid in the place of an expensive high boiling
solvent, the use of this aqueous solution proves economical.
Particularly, when this aqueous solution is capable of
absorbing the acrylic acid-containing solution in high
concentration, the use of the aqueous solution is efficient
in respect that it results in decreasing the amount of treatment
at the subsequent steps of purification. A method has been
disclosed which comprises introducing an acrylic
acid-containing gas into an absorption column, absorbing with
aqueous solution containing acetic acid thereby effecting
absorption of acrylic acid therein, and producing as the bottom
liquid of the absorption column an acrylic acid-containing
solution composed of 50 - 80 wt% of acrylic acid, 2-5 wt%
of acetic acid, and the balance of water (JP-A-1993-246941) .
This method obtains purified acrylic acid by subjecting
the acrylic acid-containing solution to azeotropic
dehydration using a mixed solution of two or more azeotropic
solvents and subsequently passing the product of dehydration
through such steps as the removal of high boiling substance.
Still another method has been disclosed which, in the
absorption with water of an acrylic acid-containing solution
resulting from a reaction of catalytic gas phase oxidation,
• comprises supplying the recovery water emanating from the
step of azeotropic dehydration to the absorption column,
supplying the resultant acrylic acid-containing solution to
a stripping column, and obtaining an acrylic acid solution
composed of 70.9 wt. % of acrylic acid, 25.6 wt. % of water,
and 2.0 wt. % of acetic acid via the bottom of the stripping
column (JP-A-2001-199931) . This method obtains purified
acrylic acid by performing azeotropic dehydration of the
acrylic acid-containing solution and subsequently subjecting
the product of dehydration to the step of crystallization.
For the purpose of obtaining crude acrylic acid
substantially destitute of water by treating an aqueous
acrylic acid solution by distillation, it is common to perform
azeotropic distillation using an azeotropic solvent. The
azeotropic distillation necessitates a step of solvent
separation in order to reuse the azeotropic solvent. In
JP-A-1993-246941 and JP-A-2001-199931 which disclose
inventions involving use of an aqueous type absorbing solvent
mentioned above, azeotropic dehydration using an azeotropic
solvent is described. Thus, the development of a method which
produces acrylic acid without a step of azeotropic
distillation has been yearned for enthusiastically.
An attempt to obtain crude acrylic acid substantially
destitute of water without performing azeotropic distillation
results in causing acrylic acid to distill in a considerable
amount from the top of the distillation column in consequence
of azeotropy between acrylic acid and water, increasing the
amount of acrylic acid expelled out of the system, and causing
degradation of yield. Under these existing circumstances,
the development of a method for producing acrylic acid in
a high yield has been yearned for.
SUMMARY OF THE INVENTION
The present inventor has found that the step of production
of acrylic acid is enabled to obviate the necessity for
azeotropic distillation by using an acrylic acid-containing
solution of high concentration, that when the acrylic
acid-containing solution is withdrawn as a column side stream
and a column bottom stream of the distillation column, obtained
solution can be separated from a high boiling substance and
a low boiling substance thereby obtaining crude acrylic acid,
and that the crude acrylic acid can be purified by
crystallization. Particularly by withdrawing the crude
acrylic acid in a gaseous form in the distillation step prior
to the crystallization, it is made possible to expel such
high boiling substances as polymerization inhibitor and a
substance causing coloration and obtain acrylic acid of high
purity through several repetitions of crystallization. This
invention has been perfected based on this knowledge.
By obtaining the crude acrylic acid from the acrylic
acid-containing solution emanating from the distillation
column of a column bottom stream and/or the column side stream
and crystallizing the crude acrylic acid according to this
invention, it is made possible to produce acrylic acid without
performing the step of azeotropic dehydration.
This invention is particularly suitable for the
purification of an acrylic acid-containing solution having
a high acrylic acid concentration. The acrylic acid of such
high concentration is attained with an effectively utilizing
use of the recycle gas at the step of absorption and decrease
the acrylic acid loss. Further, since the amount of acrylic
acid contained in the recycle gas is decreased, the catalyst
enjoys an increased service life. Moreover, the process is
simplified and the productivity is exalted because the
• purification is carried out without the azeotropic
dehydration. The invention will be described in detail below.
BRIEF DESCRIPTION OF THE DRAWING
Figure is a process diagram illustrating one example
of the preferred mode of embodying this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The first aspect of this invention is directed toward
providing a method for producing acrylic acid by a procedure
comprising steps of
a) introducing an acrylic acid-containing gas obtained
by the react ion of catalytic gas phase oxidation of raw material
of acrylic acid into an absorption column and brought into
contact with an absorbing aqueous solution thereby obtaining
an acrylic acid-containing solution,
b) distilling the acrylic acid-containing solution
without using an azeotropic solvent thereto thereby obtaining
crude acrylic acid as a column bottom stream and/or a column
side stream, and
c) supplying the crude acrylic acid to a step of
crystallization and melt crystallizing it thereby obtaining
purified acrylic acid. The bottom liquid of the step of b)
mentioned above may be supplied to a device for decomposing
acrylic acid dimer so as to recover acrylic acid. Thus, the
acrylic acid can be produced in a high yield. One example
of the preferred mode of embodying this invention will be
described below with reference to The Figure.
First, such a molecular oxygen-containing gas as air
3, such raw material 1 for acrylic acid as propylene and/or
acrolein, and a diluting gas 5 are mixed. At this step, after
the completion of the step of absorbing acrylic acid, a recycle
• gas 34 which is discharged via the top of the absorption column
may be also mixed with air, propylene and/or acrolein, and
diluting gas. The resultant mixed gas (hereinafter referred
to occasionally as "raw material gas") is supplied to a reactor
20 packed with a catalyst 10 for catalytic gas phase oxidation
and subjected to the reaction of catalytic gas phase oxidation
so as to obtain an acrylic acid-containing gas 25. This gas
25 is supplied to the bottom of an absorption column 30 and
an absorbing aqueous solution 33 is supplied via the top of
the absorption column 30 and the acrylic acid-containing gas
25 and the absorbing aqueous solution 33 are brought into
mutual contact. In this specification, the part of a
discharged gas 32 via the top of the absorption column 30
which is circulated to the reactor will be referred to as
"recycle gas" and the part thereof which is discarded to the
out side of system will be referred to as "waste gas." In
this invention, only the recycle gas 34 is introduced into
a cooling column 36, cooled by gas-liquid contact with an
absorbing water 33' newly supplied into the system and enabled
induce condensation of a condensable substance contained in
the recycle gas, and thereafter circulated to the reactor
20. The condensate so formed may be mixed with the absorbing
water 33' mentioned above and supplied as the absorbing aqueous
solution 33 to the absorption column 30. By adjusting the
temperature of the top of the absorption column with a heat
exchanger 37 disposed in the absorption column and cooling
the recycle gas, it is made possible to obtain an acrylic
acid-containing solution 35 containing acrylic acid of high
concentration via the bottom of the absorption column.
The acrylic acid-containing solution 35 is supplied to
an acrolein separation column 31, which separates the
contained acrolein from the solution and delivers an acrylic
• acid-containing solution 35' having the acrolein content
decreased via the bottom of the column. Incidentally, when
the distillate from the top of the separation column 31 is
circulated to the bottom of the absorption column 30, the
acrylic acid distilled in conjunction with acrolein can be
effectively recovered.
Then, the acrylic acid-containing solution 35' is
supplied to the intermediate stage of a first distillation
column 40 so as to remove the contained low boiling substance
via the top of the column and then produce crude acrylic acid
41 substantially destitute of water as a column side stream.
When the crude acrylic acid 41 is supplied to a crystallizing
device 50, acrylic acid 60 is obtained as a finished product.
The high boiling substance contained in bottom liquid 43 of
the first distillation column 40 contains acrylic acid dimer.
Thus, the bottom liquid 43 is supplied to a second distillation
column 70 provided on the bottom thereof with a thin layer
evaporator 73 so as to concentrate the acrylic acid dimer
and then the dimer is retained in a dimer decomposing tank
75 so as to effect thermal decomposition of the dimer into
acrylic acid. This acrylic acid is circulated via the second
distillation column 70 to the first distillation column 40
so as to recover as a finished product.
This invention is characterized by effecting
distillation of the acrylic acid-containing solution without
addition of an azeotropic solvent thereto as described above.
Advisably, therefore, the acrylic acid content of this
solution exceeds 80wt. %, preferably 85 wt. %, and particularly
87 wt. %. When the distillation is carried out in the absence
of an azeotropic solvent while the acrylic acid content falls
short of 80 wt. %, huge utilities are required for obtaining
crude acrylic acid from the bottom and the side of the
distillation column and the distillation column itself is
inevitably required to be enlarged. This invention is aimed
at providing a method for producing acrylic acid in a high
yield with lowered acrylic acid loss without steps of
azeotropic dehydration and solvent recovery.
In the present specification, the term "low boiling
substance" refers to a substance having a lower boiling point
than acrylic acid in the normal state and the term "high boiling
substance" refers to a substance having a higher boiling point
than acrylic acid in the normal state. The term "azeotropic
solvent" refers to a solvent which forms an azeotropic mixture
with water. The azeotropic solvents enumerated in
JP-A-2001-19931 may be cited as concrete examples. The term
"condensable substance" refers to a substance which is a liquid
under the atmospheric pressure, the term "distillation"
refers to a method which comprises heating a solution to the
boiling point thereof and separating a volatile component
contained therein, the term "stripping (in distillation)"
refers to a method which comprises supplying a stripping gas
and causing a target substance in a solution to pass into
the gas phase, and the term "crystallization" refers to an
operation of producing crystals from the liquid phase and
the gas phase. Then, the term "step of dynamic
crystallization" refers to a method of crystallization which
induces movement of the liquid phase by forced convection
caused with a pump etc. during crystallization and the term
"step of static crystallization" refers to a method of
crystallization which induces movement of the liquid phase
exclusively by spontaneous convection requiring no pump. Now,
this invention will be described in detail below.
(1) Step of acrylic acid absorption
For the purpose of obtaining an acrylic acid-containing
• solution of high concentration, it is necessary either to
decrease the amount of a water component introduced into the
system or increase the amount of a water component discarded
to the out side of system. For the purpose of minimizing
the acrylic acid loss discarded to the out side of system,
it is advisable to recycle the exhaust gas emanating via the
top of the absorption column to the reactor. In this invention,
by cooling the recycle gas thereby decreasing the amount of
a water component forwarding the recycle gas to the reactor,
it is made possible to decrease the amount of the water
component introduced into the absorption column and obtain
an acrylic acid-containing solution of high concentration
while the acrylic acid loss is decreased. When the whole
amount of the discharged gas from the absorption column is
cooled and even the amount of the water component discarded
to the out side of system is consequently decreased, the
absorption ratio of acrylic acid is not enhanced but degraded
far more than when the cooling is omitted. Thus, the part
of the discharged gas of the acrylic acid absorption column
which is recycled to the reactor, namely the so-called recycle
gas, alone is cooled so as to induce condensation of the water
component and enhance the absorption ratio of acrylic acid.
The cooling of the recycle gas results in inducing condensation
of not merely the water component but also the acid component,
effecting a decrease in the amount of the aid component supplied
to the reactor, and eventually preventing the catalyst from
being deteriorated by the acid. The condensate produced by
this cooling may be returned to the absorption column or
discharged to the out side of system instead of being so
returned. Though the ratio of acrylic acid loss is not varied
very much between these two choices, the return of the
condensate to the absorption column is at an advantage in
obviating the necessity for the disposal of the waste liquid.
The decrease of the amount of the water component
introduced into the system may be accomplished by a method
which comprises removing the water component contained in
the molecular oxygen-containing gas to be supplied to the
reactor and thereafter advancing the gas to the reactor.
In this invention, propylene and/or acrolein can be used
as the raw material gas of acrylic acid. While the reactor
20 does not need to be particularly restricted but is only
required to be capable of performing a reaction of catalytic
gas phase oxidation. The shell-and-tube type reactor can be
used advantageously in respect that it excels in the efficiency
of reaction. By packing the reactor 20 with the well-known
catalyst 10 for catalytic gas phase oxidation and then bringing
the raw material gas into contact with such a molecular
oxygen-containing gas as oxygen or air, it is made possible
to effect the oxidation of the raw material gas. When
propylene is used as the raw material gas, the propylene
concentration is in the range of 7 - 15 vol% and the molecular
oxygen concentration is such that the ratio of propylene :
molecular oxygen (by volume) falls in the range of 1 : 1.0
- 2.0. Air may be used as the source of supply of molecular
oxygen. When the air contains a water component, it is
preferred to be dehumidified prior to the supply thereof to
the reactor. The dehumidification is preferred because it
is capable of decreasing the amount of water introduced into
the reactor and consequently decreasing the amount of water
introduced to the absorption column. It is permissible to
use an oxygen-enriched air or purified oxygen in the place
of air. As concrete examples of the diluting gas 5, nitrogen,
carbon dioxide, and other inert gases may be cited.
In this invention, the recycle gas may be introduced
• into the reactor after it has been cooled to induce condensation
of a condensable substance. When the recycle gas is used in
this manner, the recycle gas is deprived of the water component
in advance so that the water concentration in the raw material
gas supplied to the reactor falls in the range of 0 - 10 vol%,
preferably in the range of 0 - 7 vol%, and particularly in
the range of 0 - 6 vol%. If the concentration exceeds 10 vol%,
the excess will possibly result in causing the water component
supplied via the reactor to the absorption column to increase
the ratio of acrylic acid loss. The total acid concentration
is so adjusted at to fall in the range of 0 - 0.2 vol% and
more preferably in the range of 0 - 0.1 vol%. If the total
acid concentration exceeds 0.2 vol%, the excess will possibly
result in accelerating the deterioration of the catalyst by
oxidation. The recycle gas contains unaltered propylene and
acrolien, oxygen, diluting gas, etc. in addition to the water
component and the acid component. The propylene, oxygen,
water component concentration, and total acid concentration
mentioned above can be easily adjusted by computing the amount
of the water component contained in the recycle gas and the
amount thereof to be incorporated in the raw material gas
so as to enable the water component concentration and the
total acid concentration in the raw material gas to fall in
the optimum ranges mentioned above and computing the propylene
concentration and the oxygen concentration in the recycle
gas thereby deciding the amount of propylene and the amount
of air to be newly supplied to the reactor. The term "total
acid" as used herein refers to compounds having a carboxyl
group. The recycle gas contains acrylic acid, formic acid,
and acetic acid as compounds answering the description.
The reaction of catalytic gas phase oxidation performed
by using propylene as the raw material is generally carried
out in two stages by the use of two kinds of catalyst 10 for
catalytic gas phase oxidation. The catalyst for the first
stage of this reaction is capable of forming acrolein mainly
by the gas phase oxidation of the raw material gas containing
propylene in a gas phase and the catalyst for the second stage
of the reaction is capable of forming acrylic acid mainly
by the gas phase oxidation of the raw material containing
acrolein. As the catalyst for the first stage of the reaction,
a complex oxide containing iron, molybdenum, and bismuth may
be cited. As the catalyst for the second stage of the reaction,
a catalyst having vanadium as an essential component may be
cited.
The Figure depicts the mode of performing the two-stage
reaction mentioned above with a single reactor. Optionally,
these reactions may be performed in a tandem system having
two different reactors connected to each other. The acrylic
acid-containing gas 25 which is obtained by the reaction of
catalytic gas phase oxidation contains 5-14 vol% of acrylic
acid, 0.1 - 2.5 vol% of acetic acid, 0.5-3 vol% of molecular
oxygen, and 5-36 vol% of water and other components which
are by-products of reaction such as the unaltered component
of the raw material gas, propionic acid, maleic acid, acetone,
acrolein, furfural, formaldehyde and COx.
In the acrylic acid absorption column 30, any of the
known methods of contact may be used for establishing contact
between the acrylic acid-containing gas and the absorbing
aqueous solution. As concrete examples of such methods of
contact, crossflow contact devices using a bubble-cap tray,
a uniflat tray, a perforated tray, a jet tray, a valve tray,
and a venturi tray; and counter current contact devices using
a turbo-grid tray, a dual flow tray, a ripple tray, Kittel
tray, gauze type, sheet type, and grid type structuredpackings
and random packings may be cited.
As the absorbing aqueous solution 33 to be used in this
invention, a wide variety of aqueous solutions which are
capable of absorbing acrylic acid are available. The
condensate resulting from cooling the recycle gas may be used
as the absorbing aqueous solution. Since the condensate often
contains acrylic acid, it is preferred to be reused as the
absorbing aqueous solution. The temperature of the absorbing
aqueous solution at the time of introduction falls in the
range of 0 - 50°C and preferably in the range of 10 - 40°C.
The flow rate ratio of mass of the absorbing water (which
excludes the condensate from the recycle gas and corresponds
to the absorbing water 33' shown in The Figure) to the acrylic
acid-containing gas may be properly selected to suit the target
acrylic acid concentration. The absorption of acrylic acid
is effected by counter current contact using a mass flow rate
of the absorbing water of 0.1 - 1.5 times, preferably 0.1
- 1.0 times, and particularly 0.15 - 0.8 times to the mass
flow rate of acrylic acid contained in the acrylic
acid-containing gas. If the mass flow rate ratio falls short
of the level of 0.1 times, the shortage will possibly induce
an extreme decrease of the efficiency of the acrylic acid
absorption column. Conversely, if it exceeds the level of
1.5 times, the excess will render the acquisition of an acrylic
acid-containing solution of high concentration difficult.
Incidentally, the absorbing water may contain therein for
the purpose of preventing such polymerizing substances as
acrylic acid from succumbing to polymerization one or more
compounds selected from the group consisting of N-oxyl
compounds, phenol compounds, manganese salts such as
manganese acetate, copper salts of dialkyl-dithiocarbamic
acid such as copper dibutylthiocarbamate, nitroso compounds,
• amine compounds, and phenothiazine which are cited as in
JP-A-2001-348360, 2001-348358, and 2001-348359.
The acrylic acid absorption column is generally operated
above normal pressure. In this invention, the column top
pressure (gauge pressure) is set in the range of 0 - 0.4 MPa,
preferably in the range of 0 - 0.1 MPa, and particularly in
the range of 0 - 0.03 MPa. If this pressure falls short of
0 MPa (gauge pressure), the shortage will necessitate a
pressure decreasing device and consequently add to the cost
of equipment and the cost of utilities. Conversely, if the
pressure exceeds 0.4 MPa (gauge pressure), the excess will
possibly require the temperature of the absorption column
to be elevated considerably for the purpose of discharging
a low boiling substance from the column top and consequently
degrade absorption efficiency. The column top temperature
falls generally in the range of 30 - 85°C and particularly
in the range of 40 - 80°C. In this invention, the acrylic
acid-containing solution 35 comprising 80 - 98 wt. % of acrylic
acid, 1 - 19 wt. % of water, and 1 - 10 wt. % of impurities
(such as acids like acetic acid, maleic acid, and propionic
acid, and aldehydes like furfural formaldehyde) is obtained
under the conditions of absorption mentioned above.
The method for cooling the recycle gas does not need
to be particularly restricted. It is only required to resort
to a device which is capable of condensing the condensable
substances contained in the recycle gas. As concrete examples
of the device answering the description, the shell-and-tube
type heat exchanger, fin tube type heat exchanger, air cooled
heat exchanger, double pipe heat exchanger, coil type heat
exchanger, direct contact type heat exchanger, and plate type
heat exchanger may be cited. Since the condensate more often
than not contains such polymerizable substances as acrylic
• acid, however, the method of cooling which resorts to the
combination of the cooling column 36 and such a cooling device
39 as illustrated in the Figure is commendable in respect
that it permits easy supply of a polymerization inhibitor.
The cooling temperature of the recycle gas does not need
to be particularly restricted. When the recycle gas is cooled
condensation, the concentration of the water component
therein falls in the range of 0 - 10 vol%, preferably in the
range of 0 - 7 vol%, and particularly in the range of 0 -
6 vol% and further the concentration of the total acid falls
in the range of 0 - 0.2 vol%, preferably in the range of 0
- 0.1 vol% based on the total amount of the raw material gas
supplied to the reactor. When air is used as the molecular
oxygen-containing gas, the air contains a water component.
The amount of the water component which exists after the recycle
gas is cooled is computed from the amount of the air supplied,
the aforementioned preferred concentration of the water
component in the raw material gas and the amount of the raw
material gas supplied. The cooling of Recycle gas is carried
out till the concentration the water component reach the value
found by the computation. In this invention, the recycle gas
is cooled to a temperature which is 1 - 50°C, preferably 2
- 40°C, and particularly preferably 3- 30°C lower than the
temperature of the waste gas.
Consequently, the bottom liquid of the absorption column
having an extremely high acrylic acid concentration is not
less than 80 wt. % can be obtained.
(2) Separation of acrolein
The acrylic acid-containing solution 35 possibly
contains acrolein which is the raw material of acrylic acid.
For the purpose of removing the contained acrolein, the
solution may be supplied to the acrolein separation column
31 and subjected to a treatment for the separation of acrolein.
The separation column does not need to be particularly
discriminated but is only required to be capable of separating
acrolein. A packed column, a plate column (tray column), etc.
are available for the separation. The separation column may
be properly selected between the methods of distillation and
stripping, depending on the concentration of acrylic acid
and the concentration of acrolein in the solution. In the
case of distillation, it is advisable to set the column top
pressure (absolute value) in a range of 20 - 800 hPa, preferably
in the range of 40 - 600 hPa, and particularly in the range
of 60-400hPa. If thispressure falls short of 20hPa (absolute
pressure), the shortage will be at a disadvantage in requiring
the column, condenser, and vacuum device to be enlarged and
consequently necessitating an expense of equipment.
Conversely, if the pressure exceeds 800 hPa (absolute
pressure), the excess will be at a disadvantage in heightening
the temperature inside the separation column and consequently
adding to the possibility of polymerization. The column top
temperature falls generally in the range of 30 - 100°C and
particularly in the range of 40 - 80°C. The column bottom
temperature falls generally in the range of 40 - 110°C and
particularly in the range of 50 - 90°C. Even in the case of
stripping, the separation of acrolein can be attained by any
of the hitherto well-known methods. By using these conditions
of separation, it is made possible to decrease the amount
of acrolein and consequently obtain an acrylic
acid-containing solution 35' having an acrylic acid
concentration even not less than 80 wt. %.
(3) Distillation of acrylic acid-containing solution
The acrylic acid-containing solution 35 or 35' is
supplied to the first distillation column 40, which discharges
• a high boiling substance via the bottom thereof and a low
boiling substance via the top thereof and separates crude
acrylic acid substantially destitute of water as a column
bottom stream and/or a column side stream. The first
distillation column 40 does not need to be particularly
restricted but is only required to be capable of recovering
crude acrylic acid. A packed column, a plate column (tray
column), etc. for example, are available for the recovery.
In this invention, crude acrylic acid is obtained as
a column bottom stream and/or column side stream. Such
distillation condition is operated so that low boiling
substance such as water and acetic acid can be separated,
it may be selected depending on the concentration of acrylic
acid in the acrylic acid-containing solution 35 to be
introduced and the purity of the crude acrylic acid aimed
at. Commendably, the column top pressure (absolute pressure)
is set in the range of 20 - 400 hPa, preferably in the range
of 30 hPa - 300 hPa, and particularly in the range of 30 -
200 hPa. If this pressure falls short of 20 hPa (absolute
pressure), the shortage will be at a disadvantage in requiring
the column, condenser, and vacuum device to be enlarged and
the cost of equipment to be unduly increased. Conversely,
if the pressure exceeds 400 hPa (absolute pressure) , the excess
will be at a disadvantage in heightening the temperature inside
the distillation column 40 and adding to the possibility of
polymerization. The column top temperature falls generally
in the range of 30 - 70°C and particularly in the range of
40-60°C. Then, the columnbottomtemperature falls generally
in the range of 70 - 120°C and particularly in the range of
80 - 110°C. The distillation performed under these conditions
produces crude acrylic acid containing substantially no water
and having an acetic acid content in the range of 0 - 1.0
• wt. % as a column bottom stream and/or a column side stream
of the distillation column.
During the distillation, a polymerization inhibitor may
be added to the reflux liquid for the purpose of preventing
such polymerizable substances as acrylic acid from succumbing
to polymerization. As the polymerization inhibitor, the
aforementioned various polymerization inhibitors which can
be added to the absorbing water may be adopted.
When the column side stream is withdrawn in a vaporous
form, part of such high boiling substances as polymerization
inhibitor and substance causing coloration which are
generated within the column can be removed. Thus, high
purified acrylic acid can be obtained by performing the step
of crystallization up to several repetitions. Specifically,
since the reflux liquid flows from the top toward the bottom
of the column, a liquid collecting device disposed inside
the distillation column is capable of withdrawing the column
side stream in a liquid form. The polymerization inhibitor
which has been added to the distillation column, however,
has a high boiling point and cannot exist in a vaporous form
in the distillation column and persists as dissolved in the
liquid phase inside the column. When the column side stream
is withdrawn in a liquid state, therefore, the withdrawn liquid
inevitably entrains such involatile component such as
polymerization inhibitor. When the column side stream is
withdrawn in the vaporous form, however, acrylic acid can
be obtained in a state deprived of such nonvolatile substances
as polymerization inhibitor.
For the sake of enabling the distillation column to
withdraw the column side stream in the vaporous form while
accomplishing the inherent object of distillation, the
pressures in the column side part and the column top part
are required to be so controlled as to satisfy this relation,
pressure in the column bottom part > pressure in the column
side part > pressure in the column top part. If the pressure
in the column top part and the pressure in the column side
part are equal, the essential distillation which resides in
separating a target component by virtue of the difference
of boiling points will not be fulfilled because the whole
amount of the vapor is withdrawn from the column side part.
To be specific, control the pressure of the column top part
to the value suited for distillation by use of a vacuum device
(not shown) and then the pressure of the column side part
is made to surpass the pressure of the column top part with
the same vacuum device. By setting these differences of
pressure, it is made possible to withdraw the column side
stream in the vaporous form from the column side part.
Incidentally, the pressure of the column side part relative
to the pressure of the column top part may be properly selected,
depending on the amount of the column side stream, the position
of withdrawing in the column side part, and the amount of
impurities to be contained. The proper difference between
the pressure in the column top part and the pressure in the
column side part may be set by performing the distillation
under the pressure of the column side part which is made in
advance to surpass the pressure of the column top part and
then controlling the relevant pressures based on the
composition of the produced column side stream and the amount
of distillation.
In this invention, the term "column side stream" means
the flow drawn from the column side part of the distillation
column and the term "column side part" means the position
excluding the column top part and the column bottom part.
The position for withdrawing the column side stream, therefore,
may be properly selected anywhere in the column side part,
depending on the target substance for distillation and the
conditions of distillation. For the purpose of efficiently
removing the involatile component in the plate column, for
example, it is appropriate to have a withdrawing port disposed
above the pertinent plate in the column so as to allow only
the vaporous substance to be withdrawn but not allow the liquid
on the plate to be withdrawn.
This invention is characterized by obviating the
necessity of using an azeotropic solvent. Since the acrylic
acid-containing solution of high concentration can be
prepared at the step of absorption, such low boiling substances
as water and acetic acid which are contained in the solution
can be efficiently separated as the column top distillate
of the first distillation column 40 without requiring use
of an azeotropic solvent. Further, the use of an azeotropic
solvent possibly results in inducing oil-water separation
in the distillation column during the azeotropic dehydration
and hindering the effect of preventing polymerization because
of the local presence of the polymerization inhibitor in the
water phase or the oil phase. The stability of polymerization
in the distillation column, therefore, is effectively derived
from no use of an azeotropic solvent. The absence of the use
of an azeotropic solvent is also at an advantage in permitting
the distillate to be used as an acetic acid-containing aqueous
solution without entailing oil-water separation. It has been
found that the azeotropic distillation becomes substantially
inf easible when the acrylic acid concentration in the acrylic
acid-containing solution exceeds 80 wt. %. If an azeotropic
solvent is used during the distillation of the acrylic
acid-containing solution of such high concentration, the
separation between the oil phase (azeotropic solvent phase)
and the water phase will become difficult owing to the high
acrylic acid concentration in the distillate. Even if this
separation is attained, the water phase will have the
azeotropic solvent dissolved therein in a large amount. When
the water phase containing acrylic acid is directly circulated
to the absorption column, therefore, the azeotropic solvent
is circulated also to the reactor and consequently suffered
to deteriorate the catalyst and curtail the service life of
the catalyst. On the other hand, if the acrylic acid
concentration on the distillate is lowered, the crude acrylic
acid is consequently compelled to contain the azeotropic
solvent in a large amount, it becomes difficult to obtain
the crude acrylic acid having purity enough for a finished
product even by performing the crystallization up to several
repetitions.
When the distillation is performed with no use to
azeotropic distillation as contemplated by this invention,
azeotropy occurs between the acrylic acid and water, induces
distillation of a considerable amount of acrylic acid from
the column top part of the distillation column, and entails
acrylic acid loss. In this invention, therefore, it is
appropriate to circulate the distillate of the distillation
column to the absorption column to recover the acrylic acid
contained in distillate in the absorption column.
The position at which the column top liquid of the first
distillation column circulated toward the absorption column
enters the absorption column does not need to be particularly
restricted but is only required to be different from the top
of the absorption column. The term "different from the column
top" refers to a number of theoretical plate in the range
of 2 - 100 as counted on the assumption that the number of
theoretical plate 1 represents the top of the distillation
• column and the number of theoretical plate 100 represents
the bottom thereof. The top liquid of the first distillation
column contains such low boiling substances as water and acetic
acid. In the absorption column, acrylic acid is absorbed by
the absorbing aqueous solution 33 which falls from the top
of the column. In this case, the absorption ratio of acrylic
acid is enhanced by introducing acetic acid via any of the
positions excluding the top of the absorption column. Though
the mechanism responsible for this enhancement of the
absorption ratio remains yet to be clarified, it may be
logically explained by a supposition that when the acetic
acid is introduced via any of the positions of the absorption
column 30, a layer of acetic acid gas is formed in the
neighborhood of the position for supply of the acetic acid
and the gas distribution in the absorption column is so changed
as to form a low boiling substance gas layer above the acetic
acid layer and a high boiling substance as layer under the
acetic acid layer and, as a result, acrylic acid migrates
toward the column bottom. This invention, by circulating the
column top liquid of the first distillation column to the
absorption column, is enabled to attain recovery of acrylic
acid and as well enhance the absorption ratio of acrylic acid
by dint of the acetic acid contained in the solution. The
position forming the destination of the circulation of the
liquid to the absorption column is properly selected so that
the acetic acid-containing solution is introduced below the
intermediate stage of the absorption column, specifically
in the range of number of theoretical plates 2 - 100, preferably
25 - 100, and particularly 50 - 100. At the column top, the
formation of the acetic acid gas layer no longer produces
an effect of enhancing the absorption efficiency of acrylic
acid but rather results in lowering the concentration of
acrylic acid on the column bottom side owing to a decrease
of the absorption ratio of acrylic acid and renders the
acquisition of an acrylic acid-containing solution of high
concentration impossible. Particularly, the amount of
acetic acid to be introduced is set at a mass flow rate 0.005
-0.20 times, preferably 0. 008 - 0.15 times, and particularly
0.01 - 0.10 times the mass flow rate of acrylic acid contained
in the acrylic acid-containing gas. If the mass flow rate
falls short of 0.005 times, the shortage will result in dulling
the effect of enhancing the absorption efficiency of acrylic
acid. Conversely, the mass flow rate exceeds 0.20 times, the
excess will result in rendering the acquisition of an acrylic
acid-containing solution of high concentration difficult.
This invention, by circulating the distillate to the
absorption column, is enabled to repress the acrylic acid
loss to the same level as is attained when an azeotropic solvent
is used.
(4) Step of crystallization of crude acrylic acid
This invention supplies the crude acrylic acid 41 to
the crystallizing device 50 to obtain acrylic acid 60 as a
finished product. The method of crystallization to be used
does not need to be particularly restricted but is required
to effect the crystallization either continuously or
batchwise. It is allowed to execute the crystallization in
one stage or in two or more stages. As a concrete example
of the continuous crystallizing device, backmixing column
crystallizer (BMC) (made by Nippon Steel Chemical Co., Ltd.)
as a column type crystallizer having a crystallizing part,
a solid-liquid separating part, and a crystal purifying part
integrated may be cited. A cooling disk crystallizer (CDC)
(made by Gouda Company of Netherlands), for example, is used
as the crystallizing part, a belt filter or a centrifugal
separator, for example, is used as the solid-liquid separating
part, and Kureha Crystal Purifier (KCP) (made by Kureha
TechnoEngineering Co. Ltd.), for example, is used as the
crystal purifying part respectively in the continuous
crystallizing device.
As concrete examples of the batchwise crystallizing
device, a layer crystallizing device (dynamic crystallizing
device) made by Sulzer Chemtech Company of Switzerland and
a static crystallizing device made by BEFS PROKEM Company
of France may be cited.
The method of multistage fractional crystallization
forms one of the advantageous modes of embodying this invention.
This method properly performs the crystallization by a step
of dynamic crystallization using a dynamic crystallizing
device provided with a tubular crystallizing device provided
with a temperature controlling mechanism for performing
crystallization, sweating, and melting, a tank for recovering
the mother liquid occurring after the sweating, and a
circulating pump for supplying acrylic acid to the
crystallizing device and adapted to transfer acrylic acid
by means of a circulating pump from a storage vessel disposed
in the lower part of the crystallizing device to the upper
part of the tube of the crystallizing device or by the
combination of a step of dynamic crystallization and a step
of static crystallization using a tubular crystallizing
device provided with a temperature controlling mechanism for
performing crystallization, sweating, and melting and
furnished in the lower part thereof with an drawing-out valve
and using a tank for recovering the mother liquid occurring
after the sweating with a step of static crystallization.
The crude acrylic acid in the liquid phase is introducef d
into the crystallizing device. Then, the solid phase
differing in composition from the introduced liquid phase
is solidified in the cooling surface. After 40 - 90 wt. %,
preferably 50 - 80 wt. % of the used acrylic acid is solidified,
the remainder of the liquid phase is immediately separated
and removed. This separation and removal is effected by
scooping out the residual phase with a pump (step of dynamic
crystallization) or causing it to flow out (step of static
crystallization) . It may be further followed by a step of
washing the crystal layer or a step of sweating, namely partial
melting-off of an impure crystal region.
When the dynamic crystallization and the static
crystallization are carried out by a multistage process, they
can be advantageously executed by the principle of counter
current, the substances crystallized in the component
processes are separated from the respective residual mother
liquids after crystallization, these crystallized substances
are supplied to respective pertinent steps involving still
higher levels of purity, and the residues of crystallization
are supplied to respective pertinent steps involving still
lower levels of purity.
Generally, all the steps in which acids of higher levels
of purity than the supplied crude acid solutions are known
as purifying steps and all the other steps are known as
stripping steps. The stripping steps are executed for the
purpose of recovering acrylic acid in the mother liquid from
the relevant purifying steps. The dynamic crystallization
attains crystallization with difficulty which increases in
accordance as the purity of acrylic acid decreases. In
contrast, the static crystallization attains crystallization
easily even when the purity of acrylic acid decreases as
compared with the dynamic crystallization. For the purpose
of exalting the ratio of recovery of acrylic acid, therefore,
• the final mother liquid of the dynamic crystallization is
further crystallized by the static crystallization.
The number of steps of crystallization to be required
depends on the degree of purity to be demanded. For the purpose
of producing acrylic acid of high purity, it is proper to
perform 1-5, preferably 2-3 purifying steps (dynamic
crystallizing steps) ,1-5, preferably 1-4 stripping steps
(dynamic crystallizing steps), and 1-5, preferably 1-3
stripping steps (static crystallizing steps) .
(5) Decomposition of acrylic acid dimer
In this invention, it is proper to use as a device for
decomposing acrylic acid dimer the combination of the
distillation column 70 provided on the bottom side thereof
with the thin layer evaporator 73 and the dimer decomposing
tank 75 for heating the bottom liquid of the vaporizing device
73 illustrated in The Figure. It is advisable to have the
thin layer evaporator 73 disposed on the column bottom side
because the bottom liquid of the second distillation column
70 have high viscosity. The second distillation column 70
is preferred to effect the distillation in a number of
theoretical plate in the range of 1 - 5, under a reduced pressure
in the range of 10 - 150 hPa (absolute pressure), at a column
bottom temperature of not higher than 120°C. Incidentally,
the high boiling substances contained in the bottom liquid
of the first distillation column 40 include acrylic acid dimer,
maleic acid, and polymerization inhibitor, for example.
Then, the bottom liquid of the thin layer evaporator
73 mentioned above is supplied to the dimer decomposing tank
75. This dimer decomposing tank 75 decomposes acrylic acid
dimer at a temperature in the range of 120 - 220°C. The hold
up time (capacity of dimer decomposing tank/amount of waste
oil) varies with the temperature of thermal decomposition.
• It generally falls in the range of 0.1 - 60 hours. Preferably,
it is in the range of 5 - 50 hours and particularly in the
range of 20 - 30 hours. The dimer decomposing tank, during
decomposing the acrylic acid dimer, allows addition thereto
such catalysts for decomposition as an alkali metal salt,
an alkaline earth metal salt, and an N-oxyl compound described
in JP-A-2003-89672. Particularly, the use of the N-oxyl
compound mentioned above as a polymerization inhibitor at
the step of absorption or the step of distillation is
advantageous in respect that it can additionally play as a
catalyst for decomposition of the acrylic acid dimer.
After the acrylic acid dimer has been decomposed into
acrylic acid, this acrylic acid can be effectively recovered
by supplying the product of decomposition to the thin layer
evaporator 73 and the distillate from the top of the second
distillation column to the first distillation column 40. This
invention contemplates preparing an acrylic acid-containing
solution of high concentration in the acrylic acid absorption
column 30 and preventing the acrylic acid-containing solution
of high concentration from polymerization by the addition
of a polymerization inhibitor. At the step of absorption and
the step of purification, the polymerization inhibitor is
used in amounts proportional to the concentrations of acrylic
acid. Since the polymerization inhibitor is expelled to the
out side of system as the waste liquid of the dimer decomposing
tank 75, the acrylic acid 60 produced as a finished product
enjoys high purity.
Incidentally, in this invention, acrylic acid may be
distilled out of the top of the second distillation column
70, circulated to the absorption column 30 and the first
distillation column 40, and consequently recovered as crude
acrylic acid.
The residual mother liquid recovered from the
crystallizing device 50 may be supplied in its whole amount
to any of the absorption column 30, the first distillation
column 40, the second distillation column 70, the thin layer
evaporator 73, and the dimer decomposing tank 75. It may be
partly expelled to the out side of system as waste oil. When
the whole amount of the residual mother liquid is supplied
to the step of decomposing the acrylic acid dimer, part of
the acrylic acid which is recovered from the step of decomposing
the acrylic acid dimer may be discharged out of the system
for the purpose of avoiding concentration of an impurity.
Otherwise, the residual mother liquid may be subjected to
a chemical pretreatment for transforming aldehydes and maleic
acid into high boiling substances before it is subjected to
the step of decomposing the acrylic acid dimer. As a result,
the acrylic acid recovered by the step of decomposing the
acrylic acid dimer is enabled to lower the impurity
concentration thereof. This operation may be carried out by
following the procedure taught in JP-A-2001-199931.
Examples
Now, this invention will be described more specifically
below with reference to working examples cited herein below.
(Example of production of catalyst)
A molybdenum-bismuth type catalyst was prepared by
following the procedure of Example 1 cited in JP-A-2000-325795.
It is labeled as "catalyst (I) ." A molybdenum-vanadium type
catalyst was prepared by following the procedure of Example
1 cited in JP-A-1996-206504. It was labeled as "catalyst
(II)."
Acrylic acid was produced by using an apparatus
illustrated in The Figure.
A reactor furnished on the outer periphery thereof with
a jacket for circulating a heat medium, containing therein
reaction tubes 25 mm in inside diameter and 7, 000 mm in length,
and provided at a position of 3,500 mm from the lower part
of the jacket with a perforated tube sheet dividing the heat
medium jacket into two halves, an upper one and a lower one,
was used. The lower part (the first reaction zone) and the
upper part (the second reaction zone) of the reactor had their
temperatures controlled by circulation of their respective
heat media. The reactor was packed with (1) ceramic balls
having an average diameter of 5 mm, (2) a mixture of catalyst
(I) and ceramic balls of an average diameter of 5 mm at a
volume ratio of 70 : 30, (3) catalyst (I), (4) raschig rings
made of stainless steel and measuring 5 mm in outside diameter,
4.5 mm in inside diameter, and 6 mm in length, (5) a mixture
of catalyst (II) and ceramic balls of an average diameter
of 5 mm at a volume ratio of 75 : 25, and (6) catalyst (II)
placed sequentially from the lower part toward the upper part
of the reactor in respective bed lengths of 250 mm, 700 mm,
2,300 mm, 500 mm, 600 mm, and 1,900 mm.
To the first reaction zone of the reactor, propylene,
air (the concentration of water component 2 wt. %), and part
of the discharged gas (recycle gas) from the absorption column
were circulated to supply 8.0 vol% of propylene, 14.4 vol%
of 02, and 2.0 vol% of H20 (the remainder comprising N2, propane,
COx, acrylic acid, and acetic acid) with the respective flow
rates and the cooling temperature of the recycle gas so adjusted
as to set the space velocity in the first reaction zone at
1,250 hr"1 (STP) .
The heat medium temperatures of the first reaction zone
and the second reaction zone were so adjusted as to set the
degree of conversion of propylene at 97 ± 0.5 mol% and the
yield of acrolein at 1 ± 0.5 mol% under the outlet pressure,
0.15 MPa (absolute pressure), of the second reaction zone
to obtain an acrylic acid-containing gas having an acrylic
acid concentration of 16.62 wt. % at a rate of 26.74 kg/hour.
The acrylic acid-containing gas thus obtained was cooled
to 170°C with a precooler and then led to an acrylic acid
absorption column so as to be absorbed therein in the form
of an acrylic acid-containing solution.
The absorption column was a packed column filled with
structured packings and furnished with a number of theoretical
plate 21 found by computation. It was provided in the column
bottom part with a supply port for an acrylic acid-containing
gas and withdrawing port for the absorbed liquid, in the column
top part with an inlet port for the absorbing aqueous solution
and a discharge port for the gas, and in the column side part
(the 19th theoretical plate) with a supply tube for the column
top liquid from the distilling tower and further provided
with a cooling device for cooling part of the gas emanating
from the column top.
As the absorbing water, water containing hydroquinone
in an amount corresponding to 200 wt. ppm relative to the
amount of the acrylic acid in the acrylic acid-containing
gas introduced into the absorption column was supplied at
a rate of 1.16 kg/hour.
The acrylic acid absorption column was operated, with
the column top temperature set at 65.1°C, the column top
pressure at 0.11 MPa (absolute pressure), the cooling
temperature of the recycle gas at 40.6°C, and the ratio of
recycling at 29.0%.
Via the column side part, the column top liquid of the
distillation column having a composition of 58.3 wt. % of
acrylic acid, 21.7 wt. % of H20, and 20.0 wt. % of acetic acid
was supplied at a rate of 1.00 kg/hour.
Further, this acrylic acid-containing solution was
supplied to the upper part of the packed column measuring
100 mm in inside diameter and 5 m in packed height. The packed
column was operated under a column top pressure of 265 hPa
(absolute pressure) at a column bottom temperature of 70°C
kept by heating so as to effect distillation and separation
of acrolein and the like. As a result, an acrylic
acid-containing solution containing 90.0 wt. % of acrylic
acid, 4.0 wt. % of water, 3.9 wt. % of acetic acid, and 2.1
wt. % of other components (such as acids like maleic acid
and propionic acid and aldehydes like furfural, formaldehyde,
benzaldehyde, and glyoxal) was obtained via the column bottom
part at a rate of 5. 50 kg/hour. Incidentally, the gas obtained
via the column top part was supplied to the lower parat of
the acrylic acid absorption column.
Then, the acrylic acid-containing solution was distilled
in the distillation column. This distillation column was
equipped with dual flow trays having 60 plats and a distance
of 147 mm between the plates, provided in the column top part
with a distilling tube, in the central part with a raw material
supply tube, and in the column bottom part with a bottom liquid
withdrawing tube, below the raw material supply tube with
a gaseous acrylic acid withdrawing tube for which acrylic
acid is withdrawn in the gas state, and further provided at
the 57th plate from the column top with a condenser for cooling
the acrylic acid gas.
The operation of distillation was carried out, with the
column top pressure decompressed by a vacuum device (not shown)
so as to set the working pressure thereof at 100 hPa (absolute
pressure), the pressure difference between the column side
part and the column top part controlled at 99 hPa so as to
set the flow rate ratio of the gaseous acrylic acid and the
distillate from the column top part at 4 : 1, and the reflux
ration was 3.4. 4H-TEMP0 (4-hydroxy-2,2,6,6-tetramethyl
piperidinoxyl) added as a stabilizer from the reflux line
in an amount corresponding to 200 ppm relative to the acrylic
acid supplied.
Via the gaseous acrylic acid withdrawing tube, crude
acrylic acid containing 99.4 wt. % of acrylic acid, 0.3 wt. %
of acetic acid, 0.002 wt. % of acrylic acid dimer and 0.3
wt. % of other components was obtained at a rate of 4 .33 kg/hour.
The acrylic acid-containing solution obtained from the
column top part and having a composition of 58.3 wt. %, 21.7
wt. % of H2O, and 20.0 wt. % of acetic acid was circulated
to the column side part of an acrylic acid absorption column.
The bottom liquid obtained from the column bottom part
and containing 48.7 wt. % of acrylic acid and 30.2 wt. % of
acrylic acid dimer was supplied to the intermediate part of
the distillation column of the acrylic acid dimer decomposing
device.
At this time, an aqueous 20 wt. % sodium oxide solution
which was a catalyst for the decomposition of acrylic acid
dimer was added in an amount of 0.04 wt. % (as reduced to
NaOH) to the acrylic acid-containing solution tobe supplied.
The device for the decomposition of acrylic acid dimer
was composed of a distillation column furnished with 15 dual
flow trays, a thin layer evaporator, and a dimer decomposing
tank and was capable of effecting thermal decomposition under
the conditions of 140°C of internal temperature of the dimer
decomposing tank and 30 hours of hold up time. It was operated
under the conditions of 33 hPa of column top pressure and
0.9 of reflux ratio while the thin layer evaporator was
controlled so as to set the column bottom temperature at 85°C.
An acrylic acid having an acrylic acid content of 99.4 wt. %
was recovered via the column top part and circulated to the
column bottom part of the distillation column. At this time,
the yield of purification of crude acrylic acid was 97. 0 wt. %.
Then, the crude acrylic acid was supplied to a
crystallizing unit and purified therein by performing a step
of dynamic crystallization twice. Further, the residue of
crystallization at the purifying step was treated by
performing a step of dynamic crystallization three times and
a step of static crystallization twice.
The dynamic crystallization was performed by following
the procedure adopted for the operation of a crystallizing
device disclosed in JP-B-1978-41637. To be specific, this
device was a metal tube provided in the lower part with a
storage vessel and measuring 6 m in length and 70 mm in inside
diameter and was adapted to transfer the liquid in the storage
vessel with a circulating pump to the upper part of the tube
and allow the liquid to fall down the inner wall surface of
the tube in the form of a film (falling film) . The surface
of this tube was formed of a double-wall jacket. The jacket
functioned as a thermostat and controlled so as to be set
at a stated temperature. One dynamic crystallization was
performed by the following procedure.
1. Crystallization: Acrylic acid was supplied to the
storage vessel, caused by the circulating pump to fall down
the wall surface of the tube in the form of a film, and cooled
by lowering the temperature of the jackets below the
solidification point so as to crystallize about 60 - 80 wt. %
thereof on the wall surface of the tube.
2. Sweating: The circulation pump was stopped, the
jacket temperature was increased to the vicinity of the
freezing point, and the acrylic acid is caused to sweat about
2 - 5 wt % thereof. After sweating, the residual melt is pumped
out.
3. Melting: The crystals were melted by elevating the
temperature of the jacket beyond the solidification point
and the melt was scooped out with the pump.
In the foregoing operation, the temperatures and the
solidification points were made to depend on the relevant
steps performed.
The device for the static crystallization was a tube
provided in the lower part with an drawing-out valve and
measuring 90 mm in inside diameter and 1 m in length. The
surface of this tube was formed of a double-wall jacket, which
was adapted to serve as a thermostat and was controlled so
as to be set at a certain fixed temperature. One static
crystallization was performed by the following procedure.
1. Crystallization: Acrylic acid was supplied into
the tube and crystallized therein by lowering the temperature
of the jacket to below the solidification point so as to have
about 60 - 80 wt. % thereof crystallized.
2. Sweating: The residual mother liquid occurring after
the crystallization was withdrawn from the lower part of the
tube and deprived of about 15 - 25 wt. % thereof by sweating,
with the temperature of the j acket elevated to the neighborhood
of the solidification point. After the sweating, the liquid
formed by the sweating was withdrawn.
3. Melting: The crystals were melted by elevating the
temperature of the jacket beyond the solidification point
and the resultant melt was withdrawn.
As a result, acrylic acid having such a high purity as
99.94 wt. % was obtained at a rate of 4.25 kg/hour.
The acrylic acid contained 467 wt. ppm of acetic acid,
88 wt. ppm of propionic acid, 0.5 wt. ppm of furfural, and
0.6 wt. ppm of benzaldehyde.
(Comparative Example 1)
The acrylic acid-containing solution obtained in Example
1 and containing 90.0 wt. % of acrylic acid, 4.0 wt. % of
water. 3.9 wt. % of acetic acid, and 2 .1wt. % of other components
(such as acids likemaleicacidandpropionicacidandaldehydes
like furfural, formaldehyde, benzaldehyde, and glyoxal) was
subjected to azeotropic distillation with toluene used as
an azeotropic solvent.
The azeotropic distillation was carried out by using
the same device as in Example 1, with the column top pressure
set at 75 hPa and the reflux ratio at 9.5.
Crude acrylic acid containing 99. 4 wt. % of acrylic acid,
0. 3 0 wt. % of acetic acid, 0.002 wt. % of acrylic acid dimer,
and 0.3 wt. % of other component was obtained through the
gaseous acrylic acid extracting tube at a rate of 4 . 30 kg/hour.
From the column top part, a water phase containing 40.8
wt. % of acrylic acid, 24.9 wt. % of acetic acid, 27.0 wt. %
of water, and 7.3 wt. % of toluene was obtained at a rate
of 0.82 kg/hour. Since this water phase contained toluene
in a large amount, it could not be circulated to the absorption
column. If the solution was circulated to the absorption
column, it would induce supply of toluene to the catalyst
system and occur inevitably poison for the catalyst.
We Claim:
A method for the production of acrylic acid,
comprising the steps of:
a-1) obtaining an acrylic acid-containing gas by
catalytic vapor phase oxidation of a raw material of
acrylic acid such as herein described,
a-2) introducing said acrylic acid-containing gas into
an absorption column, so as to allow said gas to contact an
absorbing aqueous solution therein, to obtain an aqueous
acrylic acid solution having not less than 85% by mass of
acrylic acid content,
a-3) cooling at least a part of a gas discharged from
the top of the absorption column, and recycling the cooled
gas to a catalytic oxidation reactor, wherein the cooling
is in the range of 1-50°C. lower than when discharged from
the top of the absorption column,
a-4) recycling to step (a-2) at least a part of a
condensed liquid obtained by cooling said discharged gas,
b) distilling said acrylic acid-containing solution in
the absence of an azeotropic solvent and obtaining crude
acrylic acid as a column bottom stream and/or a column side
stream, and
c) supplying said crude acrylic acid to a
crystallization step and melt crystallizing said crude
acrylic acid and obtaining purified acrylic acid.
2. A method as claimed in claim 1, which optionally
comprises a step of supplying the bottom liquid of the
distillation column of said step b) to an acrylic acid
dimer decomposing device.
3. A method as claimed in claim 2, which optionally
comprises a step of circulating the distillate from said
acrylic acid dimer decomposing device to the absorption
column of said step a) and/or the distillation column of
said step b).
4. A method as claimed in claim 1, which optionally
comprises a step of circulating the column top liquid of
the distillation column of said step b) to the absorption
column of said step a-2.
5. A method as claimed in claim 1, wherein the acrylic
acid-containing solution obtained at said step a-2 is
treated for separation of acrolein contained therein and
then the resultant acrylic acid-containing solution is
introduced to said step b).
6. A method as claimed in claim 1, wherein the
temperature for cooling the gas discharged from the top of
the absorption column is in the range of 2-40°C. lower than
the temperature of a gas wasted from the top of the
absorption column.
7. A method as claimed in claim 1, wherein the water
content in the recycled gas is in the range of 0-10 vol. %.
8. A method as claimed in claim 1, wherein the
concentration of the total acid is in the range of 0-0.2
vol. %.
9. A method as claimed in claim 5, wherein the pressure
of the top of the column is in the range of 20-800 hPa and
the temperature is in the range of 30-100°C.
10. A method as claimed in claim 2, wherein the pressure
of the top of the distillation column is in the range of
20-400 hPa and temperature is in the range of 30-70°C.
11. A method as claimed in claim 3, wherein the
decomposition of said acrylic acid dimer is carried out at
a temperature in the range of 120-220°C. and a holdup time
is in the range of 0.1-60 hours.
12. A method for the production of acrylic acid,
comprising the steps of:
a-1) obtaining an acrylic acid-containing gas by
catalytic vapor phase oxidation reaction of a raw material
of acrylic acid such as herein described,
a-2) introducing said acrylic acid-containing gas into
an absorption column, so as to allow said gas to contact an
absorbing aqueous solution therein to obtain an aqueous
acrylic acid solution having not less than 85% by mass of
acrylic acid content,
a-3) cooling at least part of a gas discharged from
the top of the absorption column, and recycling the gas to
a catalytic oxidation reactor,
a-4) recycling to said absorption column at least part
of a condensed liquid obtained by cooling said discharged
gas,
b) distilling said acrylic acid-containing solution in
the absence of an azeotropic solvent and obtaining crude
acrylic acid as a column bottom stream and/or a column side
stream, and
c) supplying said crude acrylic acid to a
crystallization step and melt crystallizing said crude
acrylic acid and obtaining purified acrylic acid.

A method for producing acrylic acid from an acrylic
acid-containing solution of high concentration without
performing azeotropic distillation is provided. This method
of producing acrylic acid comprises steps of absorbing acrylic
acid-containing gas, distilling the acrylic acid-containing
solution without using an azeotropic solvent thereby
obtaining crude acrylic acid as a column bottom stream and/or
a column side stream, and supplying the crude acrylic acid
to a crystallizing step and melt crystallizing the crude
acrylic acid thereby obtaining purified acrylic acid.

Documents:

287-KOL-2004-CORRESPONDENCE.pdf

287-KOL-2004-FORM 27.pdf

287-KOL-2004-FORM-27.pdf

287-kol-2004-granted-abstract.pdf

287-kol-2004-granted-assignment.pdf

287-kol-2004-granted-claims.pdf

287-kol-2004-granted-correspondence.pdf

287-kol-2004-granted-description (complete).pdf

287-kol-2004-granted-drawings.pdf

287-kol-2004-granted-examination report.pdf

287-kol-2004-granted-form 1.pdf

287-kol-2004-granted-form 18.pdf

287-kol-2004-granted-form 2.pdf

287-kol-2004-granted-form 3.pdf

287-kol-2004-granted-form 5.pdf

287-kol-2004-granted-gpa.pdf

287-kol-2004-granted-priority document.pdf

287-kol-2004-granted-reply to examination report.pdf

287-kol-2004-granted-specification.pdf

287-kol-2004-granted-translated copy of priority document.pdf


Patent Number 228807
Indian Patent Application Number 287/KOL/2004
PG Journal Number 07/2009
Publication Date 13-Feb-2009
Grant Date 11-Feb-2009
Date of Filing 31-May-2004
Name of Patentee NIPPON SHOKUBAI CO., LTD.
Applicant Address 1-1 KORAIBASHI 4-CHOME, CHUO-KU, OSAKA-SHI, OSAKA
Inventors:
# Inventor's Name Inventor's Address
1 UENO KOUJI 706-12, YORO, KATSUHARA-KU, HIMEJI-SHI, HYOGO 671-1203
2 HIRAO HARUNORI 448-2, WAKU, ABOSHI-KU, HIMEJI-SHI, HYOGO, 671-1227
3 SERATA NAOKI 931-11, HAMADA, ABOSHI-KU, HIMEJI-SHI, HYOGO, 671-1242
4 YOKOGOSHIYA TAKESHI 931-11, HAMADA, ABOSHI-KU, HIMEJI-SHI, HYOGO, 671-1242
PCT International Classification Number C07C 51/43, 51/44
PCT International Application Number N/A
PCT International Filing date
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 2003-160772 2003-06-05 Japan